mbeers6

Hi Gary, I am in USA and purchased sheet of the 1mm thick teflon from McMaster-Carr. Product description is "Chemical-Resistant Slippery Teflon PTFE Sheet, White, 0.039" Thick, 6" Wide, 6" Long" https://www.mcmaster.com/catalog/129/4095/8545K12 After fitting new strips, I bled it the exact same way you describe above. Are you in UK or USA? I could mail you small strip of teflon from my sheet if you are in USA.

Feels much better! I believe the worn "seal bands" and resulting "clunk" on the rebound fork was having the same effect of way too much air vs oil. So now instead of it feeling like it had very little to no rebound dampening, it is well controlled and compliant on obstacles. Very happy I FINALLY figured it out after years of bleeding the closed cartridge different ways.

Hey Gary, use a flat 1mm washer but make sure you bend it down the middle a little so it pushes the other washer up against the valve. I haven't ridden the bike yet but it was really soft/springy before because of all the air in the cartridge. Will post reply once I ride it!

So I finally solved my rebound "clunk" issue. Guess what it was? The teflon sealing bands on the mid valve and "bleed piston". Thanks to Paul Amott at The Hell Team for posting this video and providing specs on how to make your own teflon bands (since you can't buy them anymore). I was pulling what hair I have left out trying different bleeding procedures without luck. Can't believe it was something so simple. Paul is so knowledgeable, he also told me that when gas gas was selling the wave washer (BT280614101) they wouldn't bend them. Only Marzocchhi did that and of course they are out of biz. Anyway can't thank The Hell Team enough, really glad I finally solved it. My new hand made teflon strip Here is link to Paul's part 2 of the service of Zoke forks

Great, thanks for the update Gary!

Gary, how is the spring holding up versus using wave washer? Can you provide info on what type of spring you used such as length, diameter, where you bought it, etc.? Thanks

Here's another thread with pics https://www.advrider.com/f/threads/marzocchi-fork-maintenance-de-mystefied.1018648/

It's definitely the rebound side on mine. Makes the noise even when the fork is off the bike after bleeding use hell team instructions (and others), etc.

You can order the thicker jet block oring from this place, great resource too http://www.mid-atlantictrials.com/K-101-Parts.html

Compression side is pretty straight forward however since the rebound side is closed cartridge setup you have to follow Hell Team instructions since you have fork completely apart. If you did NOT move the rod and sucked in air, then you might be alright just adding fluid to correct air gap. With that said I've had nothing but trouble with my rebound side and cannot seem to get ride of the "clunk" when it is coming back up on rebound stroke. Hopefully you have better luck than I did.

Do tell Lineaway, what's your secret?

From my 2010 Owners manual and don’t think it’s changed

Following as I'm in the same boat as you with a 2010 that I maintain religiously and has 450 hours but it is a legit green sticker so need it to last until 2025. Will be curious to hear what others have to say about dealer support since I've been mostly using places like trialsuperstore for parts. Where about in CA are you located?

Yes you need to do test with throttle wide open (engine of course off). My '17 with 375 hours tested at 145psi so I'd say try again with throttle WFO. If still that low, then you have issues.

Hey Feets, well the top photo (stock part) is showing backwards above so I probably should have found a better example I called a vendor today who has a '14 and '21 in his shop so he is going to try to look and see if the newer style guard will bolt up to the old style mount. I'll post a solution assuming I find one. Apparently KTM has no interest in supplying "legacy" parts so it will be interesting to see how availability of older parts goes next few years.